Tag Archives: Western Australia

FBICRC’s battery value chain plans accelerate with cathode precursor pilot plant launch

The Future Battery Industries Cooperative Research Centre (FBICRC) has launched its flagship project – the Cathode Precursor Production Pilot Plant – in Western Australia.

Backed by 19 industry, research and government participants, the launch represents a major step in Australia’s journey to expand its presence throughout the global battery value chain, it said.

The first of its kind in Australia, the Cathode Precursor Production Pilot Plant will establish the technology and capabilities for Australia to design and build cathode precursor manufacturing facilities on a commercial and industrial scale.

The FBICRC explained: “Cathode precursors are precisely engineered materials, the highest cost component of a cell, and a crucial element of the battery value chain. The FBICRC’s report – ‘Future Charge – Building Australia’s Battery Industries’ – identified establishing an active materials manufacturing capability as an immediate priority for Australia to move up the global value chain, which could deliver A$1 billion ($672 million) to the economy and support 4,800 jobs by 2030.”

The Cathode Precursor Production Pilot Plant capitalises on Australia’s strong position in mining and its emerging battery metal refining industry. The facility will link with other FBICRC flagship projects across Australia, including the National Battery Testing Centre at the Queensland University of Technology, battery materials research at the University of Technology Sydney, electrolyte research at Deakin University and battery anode research at the University of Melbourne.

Shannon O’Rourke, CEO of the FBICRC, said: “The launch of the Cathode Precursor Production Pilot Plant is the culmination of several years of hard work, collaboration and integration by industry-leading partners and academic institutions, to progress the current and future needs of industry. We’re delighted to see this world-class facility up and running.

“The incoming government has committed to a National Battery Strategy which will help to seize local battery manufacturing opportunities. The Cathode Precursor Production Pilot Plant will be a key enabler to build an Australian manufacturing capability.”

The global battery market is expected to grow 9-10 times by 2030 and 40-fold by 2050. In a net-zero world, between now and 2050 over A$23 trillion will be spent on batteries, according to the FBICRC. Australia is positioned to capture more of this value given it has leading resources of all raw materials required to make high performance batteries – nickel, cobalt, manganese, graphite and lithium.

Cathode precursor materials are further processed to create cathodes in the battery cell. The performance, durability, safety, and operating envelope of a cell are impacted by the properties of precursor materials. Composition, shape, and surface properties must be controlled closely to ensure a cell performs reliably over many years.

Over 18-months, the plant will run a series of test campaigns through four fully integrated and automated P-CAM production units, provided by BASF. The four units will enable the Cathode Precursor Production Pilot Plant to run different compositions and ratios of chemistries simultaneously, or to run the same chemistries under four different conditions, changing variables such as temperature, pH or stirring rate. Produced P-CAM is then lithiated, calcined and electrochemically tested at the FBICRC-funded Electrochemical Testing Facility at the Queensland University of Technology.

BHP Nickel West has also provided equipment for the precursor facility, repurposed from its nickel sulphate pilot plant.

The Cathode Precursor Production Pilot Plant will not only deliver the technical capabilities required to build commercial scale P-CAM manufacturing facilities, it will help educate and upskill the next generation for a future battery industry, it said.

O’Rourke concluded: “Australia has the potential to develop into a competitive player in the international batteries industry. The Pilot Plant launch is a significant step in developing the on-shore capabilities and industry knowledge to create thousands of jobs and add billions of dollars to our economy.”

Jessica Farrell, Asset President, Nickel West, said: “The launch of the Cathode Precursor Pilot Plant is a vital step towards developing a future growth industry here in Western Australia. The launch of this plant, made possible through the repurposing of equipment from our nickel sulphate pilot plant, will allow the FBICRC and the State Government to explore further options for a downstream battery materials manufacturing industry. This is another exciting step for BHP as a major supplier of nickel, a commodity highly sought after by car and battery manufactures across the globe.”

Project participants include: BASF Australia Limited, BHP Nickel West, Queensland University of Technology, Curtin University, CSIRO, Minerals Research Institute of Western Australia, University of Technology Sydney, HEC Group Pty Ltd, JordProxa Pty Ltd, Ardea Resources Limited, IGO Limited, Blackstone Minerals Limited, Cobalt Blue Holdings Limited, Calix Limited, Alpha HPA Limited, Lycopodium Limited, ChemX Materials Limited, EV Metals Group PLC and Allkem Ltd (formerly Galaxy Resources Limited).

NRW Holdings companies win work from Wonbindi Coal, Lynas Rare Earths, Rio Tinto

NRW Holdings Limited companies Golding Contractors and DIAB Engineering have banked some significant contracts in the mining space, the biggest of which is a Mining Service Agreement with Wonbindi Coal Pty Ltd at the Baralaba North Mine in Queensland.

The Baralaba North award is valued at around A$800 million ($546 million) and continues the strong relationship between Golding and Wonbindi where Golding has provided the contract mining services at the Baralaba North Mine over the last four years.

The scope of work remains the same and includes maintaining and operating a client-owned fleet of equipment, producing an ultra-low volatile pulverised coal injection product. The pact commenced on July 1 and follows on from a Binding Letter of Intent the two companies signed earlier in the year.

DIAB Engineering, meanwhile, has been awarded two contracts with a value of circa-A$78 million.

At the Lynas Rare Earths Processing Facility in Kalgoorlie, Western Australia, DIAB has been awarded a contract for a key component of the facility, being the construction of the Filter Building used to process and further concentrate the rare earth. The works to be performed include the supply, fabrication and erection of the Filter Building, the installation of associated equipment and piping, and electrical and instrumentation installation.

DIAB will carry out all the circa-1,500 tonne fabrication works for the Filter Building at its facilities in Geraldton using around 80 local Midwest team members. A construction workforce of 60-80 will then be mobilised to site progressively over the coming months.

Lynas Kalgoorlie Pty Ltd, a wholly owned subsidiary of Lynas Rare Earths, is the only scale producer of separated rare earths outside of China. It mines and processes rare earth ore at Mt Weld, in the north-eastern Goldfields region of Western Australia. Lynas’ new processing facility in Kalgoorlie will treat rare earth concentrate from Mt Weld to produce a rare earth carbonate.

At Rio Tinto Iron Ore’s Tom Price mine in Western Australia, DIAB Engineering, has secured the supply, fabrication and installation of multiple dust suppression systems to be utilised on the Tom Price and Western Turner crusher and conveyor systems. These systems will assist in improved control and suppression of dust generated from processing activities, reducing the impacts on personnel and plant operations, it says. The project will run for approximately 12 months, employing 60 people at its peak.

Sedgman grows Western Australia presence with Onyx Projects acquisition

Sedgman says it has acquired project management and engineering company Onyx Projects, enhancing its growing Western Australia presence and offering to clients.

Onyx’s long-standing reputation, specialist technical capabilities and experience in the iron ore industry, paired with Sedgman’s minerals processing expertise, project delivery capability and experience, expands Sedgman’s service offering to clients from sustaining capital through to major greenfield development, it explained.

Onyx Projects will be re-named Sedgman Onyx and will operate as a part of Sedgman’s Australia West business unit.

Sedgman Managing Director, Grant Fraser, said: “We welcome the Onyx Projects people to the team and we’re looking forward to working with them. The addition of Onyx Projects to Sedgman will allow us to increase our offering while complementing Sedgman’s existing capabilities to provide our clients with a broader service offering.”

Onyx Projects Managing Director, Ian Beaumont, said: “In Sedgman, we are pleased to find a strategic partner that complements our current services, expands our capability and offers new opportunities to our personnel and our clients.”

Listed among the projects Onyx Projects has worked on are the likes of the Brockman 4 Camp, the West Angelas Deposit A Integrated Dewatering Project, the Koolyanobbing 11Mtpa Upgrades and the Murrin Murrin Nickel Cobalt Operation – Process Control System Services.

Sedgman and Onyx Projects will work through a transition process focused on the continuity of service to clients, Sedgman added.

Strandline kicks off Coburn open-pit development with dozer mining units

Strandline Resources says rapid construction of its 100%-owned Coburn mineral sands project in Western Australia has facilitated commencement of open-pit mine development (starter pits) two months ahead of schedule.

After successful early mobilisation of the mining contractor (MSCS) in April 2022, construction of the temporary tailings storage facility is almost finished, and pre-strip mining will commence from next week, it said.

Mine development will now run concurrently with finalising the construction of the processing and supporting infrastructure, which remains on-budget and on track for first production of heavy mineral concentrate later this year.

The Coburn definitive feasibility study, released in June 2020, outlined a mine life of 22.5 years at a mining rate of 23.4 Mt/y.

Detailed mine planning optimisation by AMC Consultants, using the latest infill drilling data, has resulted in an enhanced pit design for the first two years of the mine plan, which contains less overburden (lower strip ratio) and potentially reduced mining costs compared with assumptions contained within this study, the company noted. The strip ratio has reduced from an average of 0.7 to 0.5 over the first two years of the mine plan, due primarily to optimising and scheduling more ore closer to surface on the eastern side of the deposit.

The three dozer mining units, in the meantime, have been delivered and assembled on site, ready to be moved into position for mining first ore later this year. These dozer units were designed and constructed by Piacentini & Son and form a key part of Coburn’s efficient dry mining methodology, capable of receiving, screening and pumping ore from the mine to the processing facilities at an average rate of 3,100 t/h, based on two units in operation at any one time, Strandline says. The in-pit dozer mining units are designed to be frequently relocated as the mine progresses through the mine plan.

Commissioning of the sub-systems associated with the wet concentration plant and hybrid power station is expected to commence from July as construction verification works ramps up, the company added.

Strandline Managing Director, Luke Graham, said commencement of pre-strip mining represents another important milestone for the project, ensuring the company remains on track for first production of heavy mineral concentrate in the December quarter this year.

“Construction continues to advance strongly with commissioning of the wet concentration plant and hybrid power station set to commence next month,” he said.

Rio Tinto orders more Epiroc Pit Viper 271s, SmartROC D65s for Pilbara iron ore mines

Epiroc says it has won a large order for mining equipment from Rio Tinto in Australia that will see it deliver several Epiroc Pit Viper 271 drill rigs to be retrofitted by Rio Tinto with autonomous capabilities.

On top of the Pit Viper 271s, Epiroc is set to provide SmartROC D65 drill rigs loaded with intelligent features, it said. The units will be used at the miner’s iron ore operations in the Pilbara region of Western Australia.

The order exceeds SEK150 million ($14.7 million) in value and was booked in the June quarter of 2022. It follows a large order by Rio Tinto in the March quarter of 2022, also for Pit Viper 271s, and a large order in 2021 for Pit Viper 271 and SmartROC D65 rigs, also for its iron ore mines in Pilbara.

Epiroc President and CEO, Helena Hedblom, said: “Epiroc and Rio Tinto have a long-standing partnership focused on optimising safety and productivity through cutting-edge innovation.”

The Pit Viper 271 and SmartROC D65 drill rigs, manufactured in Texas, USA, and Örebro, Sweden, respectively, are built to face the toughest conditions and will come installed with Epiroc’s Rig Control System, RCS, making them ready for automation and remote control, Epiroc noted.

Dynamic Drill & Blast formalises Parkers Range work and adds Epiroc rigs to fleet

Dynamic Drill & Blast Pty Ltd, a Dynamic Group Holdings subsidiary, says it has executed a formal contract with Aurenne Parker Range Pty Ltd for the delivery of drill and blast services at the Parkers Range gold project in the Goldfields Region of Western Australia.

Dynamic Drill and Blast has been providing services to Aurenne Parker Range at Parkers Range gold project on a periodical basis while formalising the contractual arrangement.

The company also advises that it has commenced mobilisation of three drill rigs to the Northern Goldfields Interconnect Pipeline Project located in the Midwest Region and Northern Goldfields Region of Western Australia to deliver drill and blast services to Nacap Pty Ltd for an estimated minimum period of six months.

The combined contracts are expected to generate revenue of between A$8-$10 million ($5.5-6.9 million) over the next six to 12 months.

Dynamic Drill and Blast also recently commissioned one new Epiroc T45 drill rig. The second T45 drill rig is due for delivery in July and both rigs will support ongoing operations and the recently awarded projects, it said.

Epiroc’s produces three different variants of the T45 – a SmartROC T45, a FlexiROC T45 and PowerROC T45.

Dynamic said it continues contract discussions which are at various stages with multiple parties and that it sees a sustained and strong level of enquiry resulting in a significant pipeline of opportunities for short, medium and long-term projects.

MLG Oz extends service ties with Evolution Mining at Mungari operations

MLG Oz Ltd is set to extend its relationship with Evolution Mining Limited after being selected as its preferred service provider to service its Mungari operation, located in the Goldfields region of Western Australia.

The award of the new contract for the provision of haulage and integrated site services issued under Evolution’s wholly owned subsidiary, Evolution Mining (Mungari) Pty Limited, is for an initial contract term of two years, with a provision for a further one-year extension at Evolution’s discretion. The contract, MLG says, leverages its large Kalgoorlie-based resourcing pool and off-road haulage assets.

The Mungari district, now under the single ownership of Evolution, has a significant mineral endowment with a large portfolio of resources delivering long term feed options to the company’s centrally located Mungari processing infrastructure. Mungari produced 115,829 oz of gold at an average all-in sustaining cost of A$1,453/oz ($1,003/oz) in the financial year ending June 30, 2021.

MLG founder and Managing Director, Murray Leahy, said: “We commenced our first contract with Evolution less than a year ago and we are delighted to be awarded this opportunity to enhance our long-term relationship. This contract marks a significant milestone in our pursuit to provide superior integrated services to our customers.”

The new contract will see annualised revenue with Evolution effectively double to some A$15-$18 million, MLG said. The company’s scope of works builds on the recent integration of the Kundana operations into Evolution’s Mungari portfolio, with MLG engaged to service the combined sites bulk haulage and road maintenance requirements under a single service provider arrangement.

Fenix takes control of road train haulage business to cut Iron Ridge costs

Fenix Resources says it has signed definitive agreements with Newhaul Pty Ltd to acquire Newhaul’s 50% interest in Fenix-Newhaul Pty Ltd, resulting in the consolidation of 100% ownership of the haulage business into Fenix.

Factoring in the upfront consideration of A$7.5 million ($5.2 million) in cash and 30 million Fenix ordinary shares – with contingent consideration of a further 60 million Fenix shares subject to achievement of significant value-based performance milestones – the additional cash flows generated from the consolidation of the company’s haulage operations will result in higher earnings for Fenix and higher dividends available to Fenix shareholders, it said.

Fenix-Newhaul was incorporated in October 2020 as a 50:50 joint venture company to implement the strategic alliance between Fenix and Newhaul. It was established to provide haulage and logistics services to Fenix’s Iron Ridge Project, in the Mid-West region of Western Australia, 490 km from Geraldton Port.

Fenix-Newhaul operates a fleet of 25 quad road trains which provide a daily haulage capacity to Fenix of up to 4,000 t/d. In the last 18 months, Fenix-Newhaul has hauled the equivalent of over 1.72 Mt of high-grade iron ore to Geraldton, completing over 15,000 round trips travelling almost 15 million km.

The Fenix-Newhaul business provides additional logistics support to Fenix’s operating iron ore loading facilities at Iron Ridge.

The business includes a driver change-over facility and a driver accommodation base at Cue, as well as a company-owned 110,000 sq.m depot in Geraldton with 24-hour workshop and administration support.

Fenix said the transaction will deliver lower operating costs for Fenix with additional value expected from operational flexibility advantages, as well as unlocking new growth opportunities that can now be explored for the benefit of Fenix. It quantified the former as cutting FOB costs by circa-A$10/t ($6.9 t), enabling Fenix to target total C1 FOB cash costs of circa-A$70/t (wet).

Rob Brierley, Managing Director of Fenix, said: “Consolidation of Fenix-Newhaul ownership is an important strategic initiative as it immediately reduces our haulage costs. It provides Fenix with a significant advantage over our peers given haulage costs are the largest cost input for Mid-West iron ore miners.”

John Welborn, Chairman of Fenix, said: “Fenix-Newhaul is a highly profitable state-of-the-art logistics business which is an essential component of Fenix’s business success. Consolidating 100% ownership is a smart move which will reduce our costs and provide operational flexibility. These advantages will make our business significantly more resilient and robust to commodity price volatility. The transaction is a key outcome from the board’s recent strategic review and provides Fenix with a vastly improved platform to evaluate and acquire further growth opportunities.”

Maptek machine learning trial points to future of mineral deposit modelling

A trial of Maptek DomainMCF at an underground metals mine has concluded that machine learning will most likely become the preferred modelling method for mineral deposits, according to the software company.

DomainMCF is a platform that Maptek says will ‘put the geology back into geologists’, applying deep learning and big data computing methods to generate domain boundaries directly from drill hole sample data. Such rapid generation of resource models is a game changer for operations, according to Maptek.

In the trial of DomainMCF, geologists at the IGO Limited Nova-Bollinger underground mine in Western Australia trialled the solution’s machine-learning tools for modelling its resource.

Nova-Bollinger is 700 km due east of Perth, with the operation mining and processing nickel-copper-cobalt sulphide ores.

Traditional resource modelling is based on a drill hole database containing 99 lithological and 11 sulphide mineralisation logging codes. From this database the mine geologists use implicit modelling to interpret 22 different domains – 21 sulphide domains and one all-encompassing waste halo domain.

The block modelling process is undertaken annually by a team of geologists on site and in the Perth corporate office, taking several months to complete. The team trialled DomainMCF in parallel to the standard workflow as part of the 2020 resource update.

The required inputs for DomainMCF are a csv file comprising drill hole database or composite data, and an optional upper and lower surface to define the spatial extents of the region to be modelled. A block model parameter file details the origin of the block model, the 3D spatial extents and the block/sub-block dimensions.

Grade estimates are done on a 6 m x 6 m x 2 m block size and sub-blocks are permitted down to a quarter of the parent block size, according to Maptek.

During the trial, three primary tests were run using different versions of the drill hole file to explore the capabilities of the application and see how they compared to the existing workflow.

Test 1 provided DomainMCF with the drill hole composite file for the 22 different domains. Six chemical elements (Ni, Cu, Co, Fe, Mg and S) were provided to assist with the training phase of the machine-learning algorithm.

For Test 2, the data used in the first test was augmented with lithology coded data from the drill hole information outside the estimation boundary limits. The chemical variables were again used to help train the algorithm.

The purpose of this test was to determine if a combined sulphide and lithological model could be produced, and to see if giving DomainMCF additional information would impact the prediction of sulphide domains.

A hands-off approach was used in Test 3 to see how DomainMCF modelled a file containing only mineralisation codes and the grouped lithology used for Test 2. None of the domain codes from Test 1 were used.

Test 3 examined if the DomainMCF model was comparable with a manually-coded domain model and whether it was useful in the mineral resource estimate process.

IGO Senior Mine Geologist, Fletcher Pym, presented the trial results in a paper to the AusIMM International Mining Geology Conference 2022 in March.

“We were able to run Test 3, which was a relatively complicated model, in 45 minutes,” Pym said.

For Pym, Test 3 also showed that machine learning can produce very comprehensive models without the strong influence of a geologist.

Because machine learning made resource modelling much faster, senior staff had more time to focus on training less experienced core loggers. Improving the processes resulted in better quality drill hole logging, according to Maptek.

Pym added: “Machine learning will become particularly attractive if the process can not only model geological domains, but also return reliable grade estimates for mine planning across the full range of mineralisation styles.

DomainMCF model section

“Providing a well-understood confidence measure can assist in risk quantification of both geology and grade.”

The study, Maptek says, highlighted several advantages of machine learning:

  • The inputs required for machine-learning processing can be readily prepared in most resource modelling software;
    Machine learning modelling times are relatively short;
  • The pay-by-use business model is more cost-effective than maintaining implicit modelling software systems;
  • The machine learning model returns an objective measure of uncertainty in the geological model, which is likely to be useful in mineral resource classification and mining reconciliation work; and
  • Multiple different geological models can be prepared in parallel, meeting the JORC requirement to investigate ‘the effect, if any, of alternative interpretations on mineral resource estimation’.

Maptek Technical Lead for DomainMCF, Steve Sullivan, says he is excited at the potential of machine learning for revolutionising resource modelling.

“I’m amazed at the response – we are already seeing companies subscribe to DomainMCF for use in domain modelling for their 2022 resource reports,” he said.

“Machine learning works best when all the available data is presented, as shown in Test 3. The more data the better.

“The industry is struggling to find experienced personnel during the current mining boom, so embedding years of experience into smart systems helps get the job done on time and under budget.”

Maptek continues to work on proposed enhancements following feedback from industry trials of DomainMCF, with grade trend prediction added in the March 2022 release.

This is an edited version of an article that appeared in Maptek’s Forge newsletter.

Gold Fields Agnew to decarbonise crushing operations with new Sandvik solution

Gold Fields’ Agnew mine in Western Australia is continuing to innovate, with its latest technology development involving the installation of a new modular Sandvik Rock Processing Solutions crushing system that can align with its day-time solar generation capabilities on site.

The operation has recently completed one of the biggest hybrid renewable projects in the mining sector – one that includes solar, wind, battery storage and a backup gas turbine (the Agnew Hybrid Renewable Power Station). This project has put the mine on track to source some 60% of its overall energy needs from renewables.

At the same time as this, Agnew is also testing out battery-electric equipment to further decarbonise its operations, which consist of two underground mines (Waroonga and New Holland) amalgamated into the Agnew One Mine Complex.

The innovative integrated thinking has gone further than this, with a planned plant throughput increase looking to leverage as much renewable energy as possible.

In this latest project, the mine has invested A$35 million ($25 million) in the construction of a new modular crusher. The latest milestone has seen all the concrete in the construction of the project poured, with the southern run-of-mine (ROM) access ramp completed and the final stage of backfilling of the ROM wall having commenced.

The construction team are 60% of the way through erecting the crusher structure and all key crusher components – crushers, screens, feeders, magnets and metal detectors – are on site.

IM put some questions to the Agnew Technical Team to find out more about this project.

IM: Are you able to share what type of crusher the new installation is? Could you also mention what crusher model it is replacing?

ATT: We opted for a Sandvik solution (modular plant solution and automation-ready). There were several reasons for going with Sandvik and deciding on a modular-style plant. This choice has now proven beneficial two years down the track with the challenges we have seen obtaining steel and fabrication services around the globe during COVID. We began early design work with Sandvik back in June 2020, however, we also worked through various other design and equipment options with other key crushing and screening suppliers on the market.

Gold Fields were involved in the design of the circuit as the configuration needed to accommodate for potential production increases in the future, whilst also efficiently crushing the current throughput rates.

The Gold Fields project team managed the electrical design through a third-party electrical engineering company. The automation and control philosophy has been undertaken in-house by the Gold Fields Process Control team. This has been a good opportunity to demonstrate the skills and knowledge we are now building in that space. The project has been executed by the Agnew project team with an external engineering firm.

We are installing a CJ412 primary jaw crusher, two 840i cone crushers (secondary and tertiary), a double-deck product screen and several bits of auxiliary equipment such as magnets, weightometers and a rock breaker above the jaw crusher. The process design criteria was 1.7 Mt per annum with a P80 of 6 mm. The circuit replaces a JW42 jaw crusher, three 1350Z cone crushers (one secondary and two tertiaries) and two product screens.

IM: On top of the reduction in conveyor belts (the old crusher comprised of 16 conveyor belts; the new crusher circuit has six), what other benefits is the team expecting to receive with installation of the new crusher?

ATT: The new circuit will be simpler and more efficient to operate with less equipment, as well as being more modern. There are less transfer points and wear areas, which will reduce the maintenance costs associated with running the current crushing circuit.

In addition, the design and automation of the new circuit will mean the crusher is operated remotely from the main control room, removing the need for a second process operator to be situated in a standalone control room. The three Sandvik crushers have a larger capacity and slightly higher power draw, but they will produce a finer product size more efficiently based on being the latest technology on the market. This will have a positive impact upstream in the processing plant once the ore reaches the grinding circuit.

The design has included the ability to monitor the power draw of each section of the circuit, which will be fed from the Agnew Hybrid Renewable Power Station. Having the ability to crush at a higher throughput rate will also mean being able to operate the crusher more during daylight hours by taking advantage of the solar-generated power. Last year, 56% of the power Agnew draw came from renewables.

IM: When does the team plan to have the new crusher in place and commissioned?

ATT: Commissioning is scheduled for mid-August.